Weil-McLain AHE Series Manual
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Weil-McLain AHE Series Manual

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Summary of Contents for Weil-McLain AHE Series

  • Page 2: Table Of Contents

    AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Contents Please read before proceeding ................3 Prepare boiler location ..................4-7 Venting ........................ 8-13 Prepare boiler ......................14 Water piping ..................... 15-17 Gas piping ......................18 Field wiring ......................19 Jacket installation ....................

  • Page 3: Please Read Before Proceeding

    AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Please read before proceeding Installer User • This manual is for use only by your qualified Read all instructions before heating installer/service technician. installing. Follow all instructions in proper order to prevent personal •...
  • Page 4 AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Prepare boiler location — codes & checklist Installations must follow these codes: • Local, state, provincial and national codes, laws, regulations and ordinances. • National Fuel Gas Code, ANSI Z223/1–latest edition.

  • Page 5: Prepare Boiler Location

    AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Prepare boiler location — clearances Provide the following clearances: Table 1 Recommended minimum clearances Recommended minimum service clearances — See Service Enclosed cabinet, Table 1. clearances alcove or closet Recommended clearances for enclosed cabinet,...

  • Page 6: Venting

    AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Prepare boiler location — vent system d. Place in operation the appliance being inspected. When removing boiler from Follow the operating instructions. Adjust existing common vent system: thermostat so appliance will operate continuously.
  • Page 7 AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Prepare boiler location — air openings cubic feet for each 1,000 Btuh of total input of all Combustion air appliances: Combustion air must be ducted directly from outside Provide two openings into the space, each opening providing at least 1 square inch free area per 1,000 to the AHE boiler air intake fitting.
  • Page 8 AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Venting — vent/air intake pre-installation Do not terminate vent in window well or stairwell. General information Vent must terminate: Installations must comply with all AHE-45 — 9" from any opening where gases local, state and national codes could enter building.
  • Page 9 AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Venting — side venting installation Select location Figure 1 Side venting access to outside wall Review all connection, clearance and vent/air intake 47½" 38¼" considerations before selecting location. See Figure 1...
  • Page 10 AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Venting — side venting installation con’t Prepare mounting panel continued Determine boiler location. See Manual Section 2a Figure 4 Outside wall plate assembly on page 8 and “Select location” on page 9.
  • Page 11 AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Venting — side venting installation con’t Prepare mounting panel continued Inside Figure 7 Vent slope 15. Insert wall sleeve (see Figure 32, item 1, page 44) into outside wall plate assembly.
  • Page 12 AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Venting — back venting installation Prepare mounting panel Inside Inspect boiler wall location for obstructing piping and electrical supply prior to drilling and boiler installation. Failure to do so will cause severe personal injury, death or substantial property damage.
  • Page 13 AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Venting — back venting installation con’t Prepare mounting panel Figure 9 Back venting installation continued Inside Insert inside cover plate assembly into opening. Inside wall sleeve fits into outside wall sleeve. “Up”...
  • Page 14 AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Prepare boiler — placement and setup Hang boiler on mounting panel Figure 11 Cotter pin Remove crate top and wrapper. Leave bottom skid attached to boiler to aid hanging boiler.

  • Page 15: Water Piping

    AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Water piping — general information General piping information Expansion tank Pipe as shown in Figure 12. Refer to I=B=R A correctly-sized diaphragm-type expansion tank Installation and Piping Guides for additional must be provided.
  • Page 16 AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Water piping — general information con’t Determine antifreeze quantity according to system Water treatment water content. Boiler water content is listed on page on page 3 for important information WARNING Follow antifreeze manufacturer’s instructions.
  • Page 17 AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Water piping — refrigeration systems Prevent chilled water from Figure 14 Piping refrigeration systems entering boiler Install boiler so that chilled medium is piped in parallel with the heating boiler. Use appropriate valves to prevent chilled medium from entering boiler.

  • Page 18: Gas Piping

    AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Gas piping Natural gas piping Connecting gas piping to boiler Refer to Table 4 for pipe length and diameter. Base Refer to Figure 15 for recommended gas piping. on rated boiler input (divide by 1,000 to obtain Use pipe dope compatible with propane gases.

  • Page 19: Field Wiring

    AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Field wiring For your safety, turn off electrical Wiring connections power supply at service entrance panel before making any electrical Boiler is shipped with controls completely wired. connections to avoid possible shock Electrical supply to boiler should be a separate branch hazard.

  • Page 20: Start-Up

    AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Start-up Start the boiler Final check before starting Follow the “Operating instructions” found on pages 24- boiler 25 to start the boiler. Refer to Section 8b, below, if boiler fails to start.

  • Page 21: Checkout Procedure

    AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Checkout procedure Boiler and heat distribution units filled with water or Set limit control(s) to system temperature requirements. antifreeze solution? Adjust balancing valves and controls to provide design temperature to system.

  • Page 22: Operation

    AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Operation — sequence Figure 17 shows the AHE boiler control module sequence of operation with status light indications. For more information, refer to “Troubleshooting” section beginning on page 32. Figure 17 Control module sequence of operation...
  • Page 23 AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Operation — wiring diagram Figure 18 Part number 550-141-887/0800...
  • Page 24 AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Operation — operating instructions Robertshaw 7200 gas valve FOR YOUR SAFETY READ BEFORE OPERATING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
  • Page 25 AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Operation — operating instructions continued Honeywell VR8205 and White-Rodgers 36E gas valves FOR YOUR SAFETY READ BEFORE OPERATING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
  • Page 26 AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Service and maintenance — schedule Follow the “Service and maintenance” procedures given throughout this manual and in component literature shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system.
  • Page 27 AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Service and maintenance — annual start-up The boiler should be inspected and started annually, at the beginning of the heating season, only by a qualified service technician. In addition, the maintenance and care of the boiler designated in Table 5, page 26, and explained on the following pages must be performed to assure maximum boiler efficiency and reliability.

  • Page 28: Service And Maintenance

    AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Service and maintenance — annual start-up Inspect Boiler heating surfaces Burners and base Turn off power to the boiler following “To Turn After turning off power to the boiler, remove cover Off Gas To The Appliance”...
  • Page 29 AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual continued Service Start-up Perform start-up procedures given in this manual, Cleaning boiler heating surfaces page 20. Gas boilers burn cleanly — check to Verify cold fill pressure is correct and that fill system see if flue cleaning is necessary.
  • Page 30 AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Service and maintenance — annual start-up Check/test Gas piping Circulator with mixing valve Sniff near floor and around boiler area for any indication of a gas leak. The circulator provides forced water circulation to hot Test gas piping using bubble test, per Manual Section 5, page 18, if water heating system.
  • Page 31 AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual continued Check/test continued Replace tank. Limit controls and cutoffs Inspect and test the boiler limit control. Verify Boiler relief valve operation by turning control set point below boiler See Figure 26. Inspect the relief valve and lift the lever to verify flow as temperature.

  • Page 32: Troubleshooting

    AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Troubleshooting — procedure Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Never jumper (bypass) rollout thermal fuse element or any other device except for momentary testing as outlined in “Troubleshooting charts”, found on pages 35-41.
  • Page 33 AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Troubleshooting — air pressure switch Make sure boiler water temperature must be 100 °F or cooler before starting procedure to obtain appropriate readings. Check pressure switch setting Remove both air pressure switch hoses from air pressure switch.
  • Page 34 AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Troubleshooting — control module Make sure ground wiring is installed POWER and TSTAT CIRC lights flashing wiring diagram. Good Usually indicates stray voltage on external thermostat circuit wires or return grounding is extremely important water temperature entering boiler sections has not reached 130 °F within...
  • Page 35 AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Troubleshooting — charts CHART 1 — Troubleshooting POWER light status Electrical shock hazard — Wherever you see TURN OFF POWER , follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage.
  • Page 36 AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Troubleshooting — charts continued CHART 2 — TSTAT CIRC & POWER lights flashing Electrical shock hazard — Wherever you see TURN OFF POWER , follow the instructions. Failure to follow instructions could result in severe personl injury, death or substantial property damage.
  • Page 37 AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Troubleshooting — charts continued CHART 3 — LIMIT & POWER lights flashing Electrical shock hazard — Wherever you see TURN OFF POWER , follow the instructions. Failure to follow instructions could result in severe personl injury, death or substantial property damage.
  • Page 38 AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Troubleshooting — charts continued CHART 4 — PRES SWITCH & POWER lights flashing Electrical shock hazard — Wherever you see TURN OFF POWER , follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage.
  • Page 39 AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Troubleshooting — charts continued CHART 5 — FLAME & POWER lights flashing Electrical shock hazard — Wherever you see TURN OFF POWER , follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage.
  • Page 40 AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Troubleshooting — charts continued CHART 6 — TSTAT CIRC light flashing and POWER light on steady Electrical shock hazard — Wherever you see TURN OFF POWER , follow the instructions. Failure to follow instructions could result in severe personl injury, death or substantial property damage.
  • Page 41 AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Troubleshooting — charts continued CHART 8 — Insufficient heat or no heat to system (POWER light on steady) Electrical shock hazard — Wherever you see TURN OFF POWER , follow the instructions. Failure to follow instructions could result in severe personl injury, death or substantial property damage.
  • Page 42 AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Replacement parts — base & components Figure 30 Base assembly and component parts 88739 Item Description Manufacturer Manufacturer’s Weil-McLain Item Description Manufacturer Manufacturer’s Weil-McLain number part number part number number...
  • Page 43 AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Replacement parts — jacket assembly Figure 31 Jacket assembly 88740 Item Description Boiler model Weil-McLain number number part number Jacket door 421-400-009 Jacket side panel, left AHE-45 421-400-010 AHE-60 421-400-011...

  • Page 44: Replacement Parts

    AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Replacement parts — venting Figure 32 Back and side venting mounting panel assembly 88741 Item Description Weil-McLain part number number 5-9" Wall 9-13" Wall 13-24" Wall Wall sleeve, outside 450-030-754...
  • Page 45 AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Replacement parts — trim Figure 33 Boiler trim 88742 Item Description Manufacturer Manufacturer’s Weil-McLain Item Description Manufacturer Manufacturer’s Weil-McLain number part number part number number part number part number Relief valve, ¾"...

  • Page 46: Dimensions

    AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Dimensions Figure 34 21" 5 " 7" 1½" 1½" 32½" 10½" 3½" 17 " 12" min. 13 " 4 " min. 4 " min. 24" max. 24" max. Front view...

  • Page 47: Ratings

    AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Ratings Boiler 0-2,000 feet altitude 2,000-4,500 feet Boiler model altitude I=B=R water Seasonal number (Canada) ratings content efficiency (Btuh) (gallons) (% AFUE) Input DOE Heating capacity Input Output (Btuh) (Btuh)
  • Page 48 AHE Series 4 Direct Vent Wall-Mounted Boilers — Boiler Manual Handling ceramic fiber and fiberglass materials REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS The combustion chamber lining or base insulation panels in this product contain ceramic fiber materials. Ceramic fibers can be converted to cristobalite in very high temperature applications.

This manual is also suitable for:

Ahe-45Ahe-60

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